Heat Sealing Systems and Methods, and Related Articles and Materials

ABSTRACT

A bag may be formed from a tube of high strength packaging material by forming a heat seal in the end of the tube. As part of forming the heat seal, one or more supplying apparatuses, which may be air outlets, are positioned for being in opposing face-to-face relation with, and for causing heat transfer with, at least one outer portion of the tube while a transportation system transports the tube to a nipping apparatus.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 12/616,371, filed Nov. 11, 2009, which is acontinuation-in-part of U.S. patent application Ser. No. 11/824,175,filed Jun. 28, 2007, now abandoned. U.S. patent application Ser. No.11/824,175, filed Jun. 28, 2007, claims the benefit of U.S. ProvisionalApplication No. 60/817,488, filed Jun. 29, 2006. The present applicationalso claims the benefit of U.S. Provisional Application No. 61/247,983,filed Oct. 2, 2009, and U.S. Provisional Application No. 61/278,060,filed Oct. 2, 2009. Each of the above applications is incorporated byreference in its entirety.

OTHER RELATED APPLICATIONS

Two U.S. patent applications that are both entitled HIGH STRENGTHPACKAGES AND PACKAGING MATERIALS, are both being filed on the same dayas the present application, and are identified by Attorney DocketNumbers R029 13443.1 and R029 13444.1, respectively, are bothincorporated herein by reference in their entirety.

TECHNICAL FIELD

This disclosure relates to heat sealing systems and methods and, moreparticularly, to using heat to close an end of a tube to form a bag.

BACKGROUND OF THIS DISCLOSURE

It is well known to form bags from tubes, by closing ends of the tubes.Sometimes a tube is formed from a heat sealable material, and heat isused to form a seal that closes an end of the tube. As a contrastingexample, sometimes the end of a tube is sewn closed to form a bag, suchas when the tube is constructed of a material that is not heat sealable,or in other circumstances in which a suitable heat seal may not beformed (e.g., in tubes constructed of high strength packaging material).In some situations, a heat seal is considered superior to a sewn seal.Accordingly, it is desirable to provide improvements that promote theusage of heat seals (e.g., in some tubes constructed of high strengthpackaging material).

SUMMARY OF SOME ASPECTS OF THIS DISCLOSURE

One aspect of this disclosure is the provision of improvements to asystem for sealing a tube to form a bag. A tube typically has oppositefirst and second sides that each extend between opposite ends of thetube. The opposite ends of the tubes may be “straight cut” (e.g., atleast substantially straight cut (i.e., not step cut)). The first sideof the tube includes a first outer portion of the tube and a secondouter portion of the tube, and the second side of the tube includes athird outer portion of the tube and a fourth outer portion of the tube.The tube may be at least partially constructed of a woven polymermaterial.

In accordance with one aspect, the system includes a transportationsystem for transporting the tube in a downstream direction along a path.A folding apparatus is positioned along the path for moving the firstand third outer portions of the tube relative to the second and fourthouter portions of the tube and, thereby, folding the tube into afolded-over configuration while the transportation system transports thetube proximate the folding apparatus. In the folded-over configuration,the first and second outer portions of the tube are facing substantiallytoward one another, and the third and fourth outer portions of the tubeare facing substantially away from one another. A supplying apparatus(e.g., air outlet) is positioned along the path for being in opposingface-to-face relation with, and for causing heat transfer with, at leastone outer portion of the tube while the transportation system transportsthe tube proximate the supplying apparatus. The at least one outerportion of the tube is selected from the group consisting of the secondouter portion of the tube, the third outer portion of the tube, and thefourth outer portion of the tube. A nipping apparatus is positioneddownstream from both the folding apparatus and the supplying apparatusalong the path, for receiving the at least partially heated tube in thefolded-over configuration from the transportation system. The nippingapparatus is for nipping at least the first, second, third and fourthouter portions of the tube while the tube is in the folded-overconfiguration. The nipping typically completes the folding and theforming of the seal(s).

In accordance with one aspect, the supplying apparatus comprises an airoutlet mounted for being in opposing face-to-face relation with the atleast one outer portion of the tube while the transportation systemtransports the tube proximate the air outlet. The air outlet is fordischarging air onto the at least one outer portion of the tube whilethe transportation system transports the tube proximate the air outlet,so that forced convection causes heat transfer with the at least oneouter portion of the tube.

In accordance with one aspect of this disclosure, a system for sealing atube includes a transportation system for transporting the tube in adownstream direction along a path. A first supplying apparatus (e.g.,air outlet) is positioned along the path for being in opposingface-to-face relation with, and for causing heat transfer with, a firstouter portion of the tube while the transportation system transports thetube proximate the first supplying apparatus. A second supplyingapparatus (e.g., air outlet) is positioned along the path for being inopposing face-to-face relation with, and for causing heat transfer with,a second outer portion of the tube while the transportation systemtransports the tube proximate the second supplying apparatus. The firstand second supplying apparatuses are opposite from one another, and thefirst and second outer portions of the tube are opposite from oneanother. A nipping apparatus is positioned downstream from both thefirst and second supplying apparatuses, for receiving the tube from thetransportation system and completing the folding and the forming of theseal(s).

Other aspects and advantages of the present disclosure will becomeapparent from the following.

BRIEF DESCRIPTION OF THE DRAWINGS

Having described some aspects of this disclosure in general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 is a schematic, front elevation view of a sealing system, inaccordance with a first embodiment of this disclosure.

FIG. 2 is a schematic, front perspective view of a portion of thesealing system of FIG. 1.

FIG. 3 is a schematic, front perspective view of a portion of thesealing system of FIG. 1, with a cover assembly of the sealing system ina closed configuration.

FIG. 4 is a schematic, front perspective view of the portion of thesealing system shown in FIG. 3, with the cover assembly in an openconfiguration.

FIG. 5 is a schematic, left elevation, isolated view primarily of guiderails and downstream and rearward plenums of the sealing system of FIG.1.

FIG. 6 is a schematic illustration of a representative forced air systemof the sealing system, in accordance with the first embodiment.

FIG. 7 is a schematic front elevation view of a flat tube being conveyedthrough a portion of the sealing system of FIG. 1, and it shows an upperend of the tube being bent over by an upstream diverter of the sealingsystem, in accordance with the first embodiment.

FIG. 8 is a schematic front elevation view of a portion of the sealingsystem of FIG. 1, and it shows an upper end of the tube being bentdownwardly by a downstream diverter of the sealing system, whichsubstantially completes the folding of the upper end of the tube, inaccordance with the first embodiment.

FIG. 9 is schematic and similar to FIG. 5, except for schematicallyillustrating the folded-over upper end of the tube, and showing aportion of the transport conveyor of the sealing system.

FIG. 10 is a schematic front elevation view of a portion of the sealingsystem of FIG. 1, showing the folded-over upper end of the tube beingreceived by a nipping apparatus, in accordance with the firstembodiment.

FIG. 11 is an isolated, front, top perspective view of the tube inisolation prior to having either of its ends sealed, with the tube beingslightly open and having its right and left side pleats folded inwardly,in accordance with the first embodiment.

FIG. 12 is a schematic, front elevation view of the tube of FIG. 11,with the side pleats folded outwardly and the tube in a flattenedconfiguration.

FIG. 13 is a schematic, rear elevation view of the tube of FIG. 11, withthe side pleats folded outwardly and the tube in the flattenedconfiguration.

FIG. 14 is a schematic, top perspective view of the interior of the tubeof FIG. 11 in an open configuration, with the pleats folded inwardly.

FIG. 15 is an isolated, schematic, cross-sectional view of a portion ofan exemplary packaging material from which the tube to be processed bythe sealing system may be constructed, in accordance with the firstembodiment.

FIG. 16 is a schematic, front elevation view of the bag formed from thetube by the sealing system, in accordance with the first embodiment.

FIG. 17 is a schematic cross-sectional view of a top portion of the bagof FIG. 16, with the cross section taken along line 17-17 of FIG. 16,only the cross-section being shown, and the bag not being entirelyflattened, so that a portion of the interior of the bag is shown.

FIG. 18 is a schematic cross-sectional view of a top portion of the bagof FIG. 16, with the cross section taken along line 18-18 of FIG. 16,only the cross-section being shown, and the bag not being entirelyflattened, so that a portion of the interior of the bag is shown.

FIG. 19 is a schematic cross-sectional view of a portion of a bag of asecond embodiment of this disclosure, with the cross section takensimilarly to that for FIG. 17.

FIG. 20 is a schematic cross-sectional view of a portion of the bag ofthe second embodiment, with the cross section taken similarly to thatfor FIG. 18.

FIG. 21 is a schematic cross-sectional view of a portion of a bag of athird embodiment of this disclosure, with the cross section takensimilarly to that for FIG. 17.

FIG. 22 is a schematic cross-sectional view of a portion of the bag ofthe third embodiment, with the cross section taken similarly to that forFIG. 18.

FIG. 23 is a schematic cross-sectional view of a portion of a bag of afourth embodiment of this disclosure, with the cross section takensimilarly to that for FIG. 17.

FIG. 24 is a schematic cross-sectional view of an exemplary packagingmaterial in accordance with various aspects of the present disclosure.

FIG. 25 is a schematic cross-sectional view of another exemplarypackaging material in accordance with various aspects of the presentdisclosure.

FIG. 26 is a schematic cross-sectional view of still another exemplarypackaging material in accordance with various aspects of the presentdisclosure.

DETAILED DESCRIPTION

Referring now in greater detail to the drawings, in which like numeralsrefer to like parts throughout the several views, a sealing system 20 isdisclosed in the following, in accordance with a first embodiment ofthis disclosure. In accordance with the first embodiment, the sealingsystem 20 may be like conventional closers systems that are available asModel 90-I and Model 92-I from Stonepak by Premier Tech Systems, of SaltLake City, Utah, except for variations noted in this disclosure andvariations that will be apparent to one of ordinary skill in the art.

In the following, initially the sealing system 20 is discussed primarilywith reference to FIGS. 1-6, only with very general reference to a tube22 (FIGS. 7-14) that is to have its upper end sealed closed by thesealing system 20 to form a bag 112 (FIGS. 16-18). Then, a method of thesealing system 20 processing the tube 22 is discussed very generally andbriefly with reference to FIGS. 7-10. Then, the tube 22 with its endsunsealed is discussed in greater detail with reference to FIGS. 11-14.Then, material from which the tube may be constructed is discussed withreference to FIG. 15. Then, the bag 112 constructed from the tube 22 bythe sealing system 20 is discussed with reference to FIGS. 16-18. Then,other embodiments and variations are discussed with reference to theremaining figures.

Referring to FIG. 1, the sealing system 20 includes a conventionalframe. The frame has upright supports (not shown) that support an uppersubframe 24 at a position that is elevated above a floor (not shown) orother suitable surface. The frame includes other frame components thatsupport a wide variety of mounting brackets and other components of thesealing system 20.

The tube 22 (FIGS. 7-14) that is to have its upper end sealed closed bythe sealing system 20 is introduced into an upstream end of the sealingsystem (i.e., the right-hand end in FIG. 1). The resulting bag 112(FIGS. 16-18) with a sealed closed upper end exits a downstream end ofthe sealing system 20 (i.e., the left-hand end in FIG. 1). That is, thetube 22/bag 112 travels along a path in a downstream direction throughthe sealing system 20, and the downstream direction extends along thelength of the sealing system 20. Accordingly and to provide a frame ofreference for ease of understanding, throughout this DetailedDescription section of this disclosure, the directional references to“upstream” and “downstream” are defined by/relate to the direction inwhich the tube 22/bag 112 travels through/along the length of thesealing system 20.

Referring to FIGS. 1 and 2, the sealing system 20 includes atransportation system comprising a conventional transport conveyor 26that is not novel per se. The transport conveyor 26 extends between theupstream and downstream ends of the sealing system 20, although thetransport conveyor may not extend for the entire length of the sealingsystem. The tube 22 is introduced to the transport conveyor 26 at theupstream end, and the transport conveyor carries the tube/bag throughthe sealing system 20, and discharges the bag from the downstream end ofthe sealing system.

As best understood with reference to FIG. 2, the transport conveyor 26includes a rearward pulley system 28 b that is positioned behind aforward pulley system 28 a. Each of the transport conveyor's pulleysystems 28 a, 28 b includes an endless belt 30 that extends around anupstream pulley 32 and a downstream pulley 34, and there may beintermediate pulleys (not shown) in the pulley system. The upstream anddownstream pulleys 32, 34 are supported by shafts that hang down fromthe upper subframe 24.

The transport system may be configured differently. For example, thetransport system may include multiple transport conveyors, or the like,arranged end to end. As a more specific example, the transport conveyor26 may not extend all the way to the downstream end of the sealingsystem (e.g., the folded tube 22 (FIGS. 7-9) may be passed from adownstream end of a shorter transport conveyor to another conveyor(e.g., a nip conveyor/nipping apparatus 76) that may be characterized asbeing part of the transport system).

Referring to FIGS. 1 and 2, the sealing system 20 includes aconventional upstream guide that comprises a pair of adjacent guiderollers 36 and is not novel per se. The guide rollers 36 are supportedby shafts hanging down from the upper subframe 24. The upstreamguide/guide rollers 36 are for guiding an upper portion of the tube 22,which is being transported by the transport conveyor, into an upstreamend of a guide channel 38 (FIGS. 3 and 4) defined between forward andrearward guide rails 40 a, 40 b. The guide rollers 36 may be driven,such that the guide rollers may be characterized as being part of thesealing system's transportation system (which also includes thetransport conveyor 26).

The guide channel 38 is upwardly and downwardly open. Referring to FIGS.1-4, the upper opening of the guide channel 38 may be covered andsomewhat obstructed by a cover assembly 42 that is mounted to the frameof the sealing system 20. The cover assembly 42 may, optionally, bemounted by hinges 44 (FIG. 3), so that the cover assembly may be pivotedbetween a closed configuration (FIGS. 1-3) and an open configuration(e.g., see the partially open configuration shown in FIG. 4). Morespecifically, the closed cover assembly 42 covers (e.g., obstructs,typically without fully closing) the upper opening of the guide channel38.

The cover assembly 42 comprises a substantially rigid cover plate 43that is pivotably mounted by the hinge assemblies 44 and carries othercomponents of the cover assembly 42. The cover assembly 42 includes afolding apparatus, which includes upstream and downstream diverters 46,47, for folding the tube 22 into a folded-over configuration while thetransport conveyor 26 transports the tube proximate (e.g., by, past, orthe like) the folding apparatus. The lower surface of the cover plate 43may optionally also be characterized as being part of the foldingapparatus since it may play some role in the folding of the tube 22(e.g., such as by not allowing the partially folded tube to unfold dueto any resiliency of the tube).

More specifically, the cover assembly 42 includes a conventional,concavely curved upstream diverter 46 that is not novel per se. Theupstream diverter 46 is mounted to and/or defined by the upstream end ofthe cover plate 43, for pivoting with the cover plate 43. The upstreamdiverter 46 is for initiating a folding over of the upper marginalportion of the tube 22. The upstream diverter 46 typically folds theupper marginal portion of the tube 22 downwardly about ninety degreesrelative to the lower portion of the tube, so that the upper marginalportion of the tube extends approximately perpendicularly relative tothe lower portion of the tube. For example, the upstream diverter 46 maybe defined by a concavely cut upstream end of the cover plate 43, and/orthe upstream diverter may include any suitable structure or materialthat is mounted to the upstream end of the cover plate 43 for aiding inthe folding of the upper marginal portion of the tube.

It is conventional to include a folding apparatus downstream from theupstream diverter 46 for substantially completing the folding over ofthe upper portion of the tube 22. In this regard, a curved downstreamdiverter 47 is mounted to and/or defined by the downstream end of thecover plate 43, for pivoting with the cover plate 43. The downstreamdiverter 47 is shaped (e.g., contoured) for substantially completing thefolding over of the upper portion of the tube 22, as will be discussedin greater detail below. More specifically, the downstream diverter 47typically folds what was originally the upper marginal portion of thetube 22 about an additional ninety degrees downward relative to thelower portion of the tube.

The cover assembly 42 further includes an upper heat supplying apparatus(e.g., upper air outlet 48 a (FIG. 4)) that may be any suitableapparatus (e.g., an infrared radiant heater) for causing heat transferwith at least one outer portion of the tube 22 while the transportconveyor 26 transports the tube proximate (e.g., by, past, or the like)the upper heat supplying apparatus. More specifically, the upper heatsupplying apparatus is an upper air outlet 48 a that is in the form of aplate that defines a wall of an upper plenum 50 a (FIGS. 3 and 4) andhas numerous holes (e.g., discharge ports) extending therethrough fordischarging air from the upper plenum. The upper air outlet 48 a extendsalong a portion of the length of the sealing system 20. The upper airoutlet 48 a may be a perforated plate, an air vent, louvers, an airdistributor, or any other suitable structure for discharging a flow ofair. Substantially all of the air outlet 48 a is positioned downstreamfrom the upstream diverter 46, although variations are within the scopeof this disclosure.

The upper plenum 50 a, which includes the upper air outlet 48 a, may bemounted to and/or defined by the cover plate 43, such that the upperplenum 50 a pivots with the cover plate 43. The upper plenum 50 a islocated at a position between the upstream and downstream ends of thecover plate 43. The upper plenum 50 a is typically completely closed,except for including an inlet opening and the holes of the upper airoutlet 48 a. The holes of the upper air outlet 48 a are located at alower face of the upper plenum 50 a/cover assembly 42.

The inlet opening to the upper plenum 50 a may be located at the upperside or rear side of the upper plenum 50 a/cover assembly 42. Since thecover assembly 42 is mounted for pivoting, provisions may be made sothat the supply duct connected to the inlet opening of the upper plenum50 a accommodates for the pivoting. For example, the supply duct may beflexible, or it may comprise first and second ducts fit one inside theother and between which there can be relative rotation when the coverassembly is pivoted. Alternatively, the supply duct may be removablyconnected by a removable clamp to the inlet opening of the upper plenum50 a. Any suitable connection may be used. The upper plenum 50 a is oneof several plenums of the sealing system 20, and the supply of air tothe several plenums is discussed below, after all of the plenums areintroduced.

As best understood with reference to FIG. 4, a lower heat supplyingapparatus (e.g., upstream lower air outlet 48 b and/or downstream lowerair outlet 48 c) is beneath the upper plenum 50 a/covered by the coverassembly 42 while the cover assembly is in its closed configuration. Thelower heat supplying apparatus may be any suitable apparatus (e.g., aninfrared radiant heater) for causing heat transfer with at least oneouter portion of the tube 22 while the transport conveyor 26 transportsthe tube proximate (e.g., by, past, or the like) the lower heatsupplying apparatus.

More specifically, the lower heat supplying apparatus comprises one ormore of the lower air outlets 48 b, 48 c, each of which is a plate thatdefines a wall of a lower plenum 50 b and has numerous holes (e.g.,discharge ports) extending therethrough for discharging air from thelower plenum. The lower air outlets 48 b, 48 c each extend along aportion of the length of the sealing system 20. The lower air outlets 48b, 48 c each may be a perforated plate, an air vent, louvers, an airdistributor, or any other suitable structure for discharging a flow ofair.

The lower plenum 50 b is fixedly mounted to the frame of the sealingsystem 20, so that the lower plenum is beneath the upper plenum 50 a andcovered by the cover assembly 42 while the cover assembly 42 is in itsclosed configuration. The lower plenum 50 b includes a conventionalupper section that includes the lower air outlet 48 b and is not novelper se. The lower air outlet 48 b is an upper face of the upper sectionof the lower plenum 50 b, and the lower air outlet 48 b extends parallelto, and is in opposing face-to-face relation with (e.g., is opposite),the lower face (i.e., the upper air outlet 48 a) of the upper plenum 50a.

The lower plenum 50 b includes a lower section that includes the lowerair outlet 48 c. The lower air outlet 48 c extends obliquely, downwardlyfrom the upper section of the lower plenum 50 b. The lower plenum 50 bis typically completely closed, except for including an inlet opening 53(FIG. 1), the holes in the air outlets 48 b, 48 c, and an outlet openingin communication with a passageway 54 (e.g., tube) for supplying air toan inlet opening of a downstream plenum 50 d.

Downstream heat supplying apparatuses (e.g., downstream air outlets 48d, 48 e (FIG. 5)) are covered by the cover assembly 42 while the coverassembly is in its closed configuration. The downstream heat supplyingapparatuses may be any suitable apparatuses (e.g., infrared radiantheaters) for causing heat transfer with at least one outer portion ofthe tube 22 while the transport conveyor 26 transports the tubeproximate (e.g., by, past, or the like) the downstream heat supplyingapparatuses.

More specifically, the downstream heat supplying apparatuses are thedownstream air outlets 48 d, 48 e, each of which is a plate that definesa wall of a downstream plenum 50 d and has numerous holes (e.g.,discharge ports) extending therethrough for discharging air from thedownstream plenum. The downstream air outlets 48 d, 48 e each may be aperforated plate, an air vent, louvers, an air distributor, or any othersuitable structure for discharging a flow of air.

The downstream plenum 50 d is fixedly mounted to the frame of thesealing system 20, so that the downstream plenum is downstream from theupper and lower plenums 50 a, 50 b. As schematically shown by dashedlines in FIG. 3, the downstream plenum 50 d is covered by the downstreamdiverter 47 while the cover assembly 42 is in its closed configuration.The downstream diverter 47 and/or downstream plenum 50 d are adapted(e.g., sized and arranged) so that the downstream diverter 47 fits overthe downstream plenum 50 d with clearance for allowing the folded tube22 to pass between the downstream diverter and the downstream plenum, aswill be discussed in greater detail below with reference to FIG. 9.

Referring to FIGS. 4 and 5, the downstream plenum 50 d is generally(e.g., substantially) triangular shaped in that its opposite uprightfaces/downstream air outlets 48 d, 48 e extend obliquely and divergentlywith respect to one another and downwardly from an convexly curved uppersurface of the downstream plenum. Each of the opposite uprightfaces/downstream air outlets 48 d, 48 e extends along a portion of thelength of the sealing system 20. In addition and as best understood withreference to FIG. 5, each of the opposite upright faces/downstream airoutlets 48 d, 48 e extend obliquely and convergently with respect to oneanother in the downstream direction. As a result, the upstream end ofthe downstream plenum 50 d is wider than the downstream end of thedownstream plenum. That is, the downstream plenum 50 d becomes morenarrow in the downstream direction.

The downstream plenum 50 d is typically completely closed, except forincluding the holes in the downstream air outlets 48 d, 48 e and aninlet opening in communication with the passageway 54 (e.g., tube) forreceiving a flow of air from the lower plenum 50 b. The downstreamplenum 50 d may receive its flow of air from any other suitable source.

The downstream plenum 50 d, and more particularly the downstream airoutlet 48 e, is proximate the downstream portion of the forward guiderail 40 a. An opening 56 (FIGS. 4 and 5) is defined in and extendsthrough the downstream portion of the forward guide rail 40 a, so thatthe rearward face/air outlet 48 e of the downstream plenum 50 d is inopposing face-to-face relation with the opening 56. The downstream airoutlet 48 e is configured for discharging air through the opening 56, aswill be discussed in greater detail below.

The opening 56 (FIGS. 4 and 5) that extends through the downstreamportion of the forward guide rail 40 a is arranged and sized so that therearward face/air outlet 48 e of the downstream plenum 50 d is inopposing face-to-face relation with a rearward supplying apparatus(e.g., rearward air outlet 48 f). The rearward supplying apparatus maybe any suitable apparatus (e.g., an infrared radiant heater, or simply afan or another type of conventional air mover) for causing heat transferwith at least one outer portion of the tube 22 while the transportconveyor 26 transports the tube proximate (e.g., by, past, or the like)the rearward supplying apparatus. More specifically, the rearwardsupplying apparatus is for providing a forced flow of cool air and/orair at substantially the same temperature as ambient air, for cooling aportion of the tube 22, as will be discussed in greater detail below.

More specifically, the rearward supplying apparatus is the rearward airoutlet 48 f, which is a plate (e.g., a portion of the rearward guiderail 40 b) that defines a wall of a rearward plenum 50 f and hasnumerous holes (e.g., discharge ports) extending therethrough fordischarging air from the rearward plenum. The rearward air outlet 48 fextends along a portion of the length of the sealing system 20. Therearward air outlet 48 f may be a perforated plate, an air vent,louvers, an air distributor, or any other suitable structure fordischarging a flow of air. The opening 56 in the forward guide rail 40 ais substantially rectangular and substantially corresponds to thesubstantially rectangular shape of (e.g., the pattern of discharge portsin) the air outlet 48, although different shapes and arrangements arewithin the scope of this disclosure.

The rearward plenum 50 f is fixedly mounted to the frame or anothercomponent of the sealing system 20. For example, the rearward plenum 50f may be mounted to a portion of the rearward guide rail 40 b as shownin FIG. 5, so that the rearward plenum is downstream from the upper andlower plenums 50 a, 50 b. As best understood by contrasting FIGS. 3 and4, the rearward plenum 50 f is covered by the downstream diverter 47while the cover assembly 42 is in its closed configuration. The rearwardplenum 50 f is typically completely closed, except for including theholes in the rearward air outlet 48 f and an inlet opening for receivinga flow of air. The rearward plenum's inlet opening may be located at therear side of the rearward plenum 50 f.

Air may be supplied to the plenums 50 a, 50 b, 50 d, 50 f in anysuitable manner for helping to facilitate the desired sealing of thetube 22 to form (or close) a bag 112 (FIGS. 16-18). Each of the plenums50 a, 50 b, 50 d, 50 f may be part of a forced air system that is forproviding a forced flow of air that may be heated or cooled. Each of theforced air supply systems may be at least generally conventional innature. For example and in accordance with the first embodiment, a firstforced air system includes the upper plenum 50 a; a second forced airsystem includes the plenums 50 b, 50 d; and a third forced air systemincludes the rearward plenum 50 f. Alternatively, the plenums 50 b, 50 dmay respectively be part of separate forced air systems, and/or otherarrangements of plenums/forced air systems are within the scope of thisdisclosure. For example, the forced air system comprising the rearwardair outlet 48 f may alternatively simply be in the form of a fan oranother type of conventional air mover that is for supplying a flow ofotherwise ambient air (e.g., relatively cool ambient air) for causingcooling heat transfer with the respective outer portion of the tube 22while the transport conveyor 26 transports the tube proximate (e.g., by,past, or the like) the fan or the like.

FIG. 6 schematically illustrates a forced air system 58 that may berepresentative of each of the forced air systems (which respectivelyinclude the plenums 50 a, 50 b, 50 d, 50 f) of the sealing system 20.The forced air system 58 may include a conventional air handler 60having an air inlet 62, a heating and/or coiling coil 64 (e.g., anysuitable device for changing the temperature of the flow of air, byadding and/or removing heat (e.g., a refrigeration system and/or heatingelement(s))), and a motor-operate air mover 66 (e.g., a motor-driven fanor any other suitable device for moving air).

The air supplied from the air handler 60 may flow in conventionalduct(s) 68 or any other suitable structure that is optionally equippedwith a conventional motor-operated, flow-control damper 70 or anothersuitable device. The duct(s) 68 discharge into one or more plenums 50(e.g., the respective one or more of the plenums 50 a, 50 b, 50 d, 50f), and the flow of air is discharged from the plenum(s) 50 by way ofone or more air outlets 48 (e.g., the respective one or more of the airoutlets 48 a-48 f). The air outlet 48 may include one or more holes orother openings for discharging a forced flow of air that is forproviding forced convention. For example, the air outlet 48 may be aperforated plate, an air vent, louvers, an air distributor, or any othersuitable structure for discharging a flow of air.

The plenum(s) 50 may be equipped with one or more temperature sensors 72that may be connected to a controller 74. The controller 74 may alsoconnected to the coil 64, air mover 66 and damper 70 for purposes ofcontrol. The forced air system 58 may include any other suitablecomponents such as, but not limited to, components for filtration. Inaddition and optionally, the forced air system including the plenum 50 f(FIG. 5) may omit the coil 64, and the coils 64 in the forced airsystems including the plenums 50 a, 50 b, 50 d may only be for addingheat. A variety of different forced air systems are within the scope ofthis disclosure (e.g., the types of or usage of the features of theforced air systems may vary, depending upon the types of materials,tubes 22 and bags being processed by the sealing system 20). Features ofthe controller 74 may be embodied in any suitable manner, such as insoftware, firmware and/or hardware modules, for providing control overoperation of the sealing system 20/components of the sealingsystem/forced air systems/components of the forced air systems.

Referring primarily to FIGS. 1, 2 and 10, a conventional nippingapparatus 76, which is not novel per se, is positioned downstream fromthe folding apparatus (e.g., the upstream and downstream diverters 46,47) and the supplying apparatuses (e.g., the air outlets 48 a-48 f). Thenipping apparatus 76 receives the tube 22 from the transport conveyor26. Nonetheless, the transport conveyor 26 extends all the way to thedownstream end of the sealing system 20, and the transport conveyor 26at least partially carries the tube 22/bag all the way to the downstreamend of the sealing system.

The nipping apparatus 76 performs a nipping function, but it may also becharacterized as being part of the sealing system's transportationsystem (which also includes the transport conveyor 26), since thenipping apparatus may help in carrying the tube 22/bag to the downstreamend of the sealing system 20. Also, and for example, the transportconveyor 26 may not extend all the way to the downstream end of thesealing system 20, such that the nipping apparatus 76, or anothersuitable device, completes the transporting of the tube 22 to thedownstream end of the sealing system.

As best understood with reference to FIGS. 2 and 10, the nippingapparatus 76 includes a rearward pulley system 78 b that is positionedbehind a forward pulley system 78 a. Each of the nipping apparatus'pulley systems 78 a, 78 b includes an endless belt 80 that extendsaround an upstream pulley 82, intermediate pulleys 84, and a respectiveone of the downstream pulleys 34 (FIG. 1). The upstream and intermediatepulleys 82, 84 are supported by shafts that hang down from the uppersubframe 24. The nipping apparatus 76 may be configured differently. Forexample, the nipping apparatus 76 may include multiple nippingconveyors, or the like, arranged end to end.

As best understood with reference to FIG. 1, the sealing system 20includes a conventional drive system, which is not novel per se, fordriving the respective pulleys of the transport conveyor 26 and thenipping apparatus 76, and the guide rollers 36. The drive systemincludes an electric motor 86 and a gear box 88. A drive chain or belt89, or any other suitable device for transferring rotary power, connectsthe output shaft of the motor 86 to the input shaft of the gear box 88.The respective pulleys of the transport conveyor 26 and the nippingapparatus 76, and the guide rollers 36, are driven in a conventionalmanner by way of one or more chains or belts 90, or any other suitabledevices for transferring rotary power. Some of the features of the drivesystem are hidden from view in FIG. 1 and, therefore, they areschematically illustrated by dashed lines. The one or more belts 90, orthe like, connect the output shaft(s) 88 a of the gear box 88 to therespective shafts that hang down from the upper subframe 24 and supportthe respective pulleys of the transport conveyor 26 and the nippingapparatus 76, and the guide rollers 36. One or more of the pulleys ofthe transport conveyor 26 and the nipping apparatus 76, and the guiderollers 36, may be idler pulleys or rollers that are not directly drivenby the sealing system's drive system. Any suitable drive system(s) maybe used in the sealing system 20.

The sealing system 20 may be constructed of any suitable materials. Inaddition, surfaces (e.g., metal surfaces) of the sealing system 20 thatthe tube 22 comes into sliding contact with (e.g., the foldingapparatus) may be coated with Teflon brand coating or other suitablematerials for reducing friction. The hot air supplied by the sealingsystem 20 may also help to reduce the friction associated with the tube22 sliding relative to features of the sealing system.

A method of the sealing system 20 processing the tube 22 is discussedvery generally and briefly in the following with reference to FIGS.7-10, in accordance with the first embodiment. FIGS. 7 and 8schematically show the flat tube 22 being conveyed through and foldedover by the folding apparatus (e.g., the upstream and downstreamdiverters 46, 47). FIG. 9 schematically shows the folded-over upper endof the tube 22 being conveyed between the downstream and rearwardplenums 50 d, 50 f by the transport conveyor 26. FIG. 9 is schematicbecause, for example, some of the clearances shown are exaggerated. Forexample and in the context of the tube 22 passing between the downstreamdiverter 47 (FIGS. 1-4) and the downstream plenum 50 d, typically justenough clearance will be provided for the tube to reasonably passthrough without any unwanted effects. For example, while the coverassembly 42 is in its closed configuration, the outer surface of thedownstream air outlet 48 d and the inner surface of the downstreamdiverter 47 are in opposing face-to-face configuration with one another,and the clearance between the outer surface of the downstream air outlet48 d and the inner surface of the downstream diverter 47 is typicallyjust large enough for the tube 22 to reasonably pass therethroughwithout any unwanted effects. As mentioned above, Teflon brand coatings,or other suitable materials for reducing friction, and the hot airsupplied by the downstream plenum 50 d may reduce friction and therebyaid the tube 22 in passing through the narrow clearance between thedownstream diverter 47 (FIGS. 1-4) and the downstream plenum 50 d. Forexample the upper rows of discharge ports in the downstream air outlets48 d, 48 e may be no more than about one inch from the convexly curvedtop edge of the downstream plenum 50 d, so that a sufficient amount oflubricating hot air reaches the outer surface of the convexly curved topedge of the downstream plenum. FIG. 10 schematically shows thefolded-over upper end of the tube 22 being introduced into the nippingapparatus 76 for nipping.

The tube 22 with its ends unsealed is discussed in greater detail in thefollowing with reference to FIGS. 11-14, in accordance with the firstembodiment. FIG. 11 shows the tube 22 with its optional side pleats 91folded inwardly. In contrast, the front and rear views of FIGS. 12 and13 show the pleats 91 folded outwardly, although the pleats typicallyremain folded inwardly at least until after the bag containing thepleats is filled. The pleats 91 are defined by lines of disruption 92(e.g., fold lines). FIG. 14 is a top perspective view of the interior ofthe tube 22 in an open configuration, with the pleats 91 foldedinwardly. FIGS. 12 and 13 are schematic because, for example, theyinclude dashed lines for schematically identifying that the front sideof the tube 22 includes a first outer (marginal) portion O1 of the tubeand a second outer portion O2 of the tube, and the rear side of the tubeincludes a third outer (marginal) portion O3 of the tube and a fourthouter portion O4 of the tube. FIG. 14 is schematic because, for example,it includes dashed lines for schematically identifying that the interiorsurface of the front side of the tube 22 includes first and second innerportions 11, 12 that respectively correspond to the first and secondouter potions O1, O2, and the interior surface of the rear side of thetube 22 includes third and fourth inner portions 13, 14 thatrespectively correspond to the third and fourth outer potions O3, O4.Similarly, each pleat 91 is schematically shown as including surfaceportions P1, P2, P3, P4. The pleats 91 may be omitted.

In accordance with the first embodiment, the tube 22 comprises a sheetof packaging material 100 (FIG. 15) with opposite edges that have beenjoined together at a longitudinal seal 93 (FIGS. 11, 12 and 14) thatextends been the opposite ends of the tube and may be in the form of afoldover seal, fin seal, or any other suitable seal, or the like. Inaccordance with the first embodiment and as shown in the figuresherewith, the edges at the opposite ends of the tube 22 are “straightcut” (e.g., at least substantially straight cut (i.e., not step cut)).Alternatively, the edges may not be required to be “straight cut.”

The packaging material 100 from which the tube 22 may be constructed isdescribed in the following with reference to FIG. 15, in accordance withthe first embodiment. The packaging material 100 generally includes asubstrate 102 (any suitable substrate (e.g., a high strength substrate)such as, but not limited to, paper, polymer film, or a woven polymersubstrate) and a pair of facing systems 104, 106, each of which mayinclude one or more layers that are coextruded and/or otherwise joinedto one another. Such layers may include polymer films, polymer orpolymeric coatings or layers, paper layers, other woven materials ornonwoven materials, or any other suitable material. In accordance withthe first embodiment, the substrate 102 is a woven polymer substrate,although other substrates may be used. Each facing system 104, 106 ofthe packaging material 100 includes an outermost surface 108, 110 thatrespectively defines the inner (i.e., interior) and outer (i.e.,exterior) sides or faces 108, 110 of the packaging material 100. Eachside 108, 110 of the packaging material 100 includes (or is providedwith) at least one area or zone (e.g., one or more of outer portionsO1-O4 and inner portions I1-I4) that is capable of being joined to therespective surface of the packaging material 100 using a heat sealablematerial, adhesive, or otherwise. More specifically and in accordancewith the first embodiment, the entirety of the interior and exteriorsurfaces of the tube 22 comprise (e.g., are constructed of or have hadapplied thereto) a heat sealable material.

A bag 112 (FIGS. 16-18) formed form the tube 22 by the sealing system20, and an example of a suitable method for forming the bag, arediscussed in the following, in accordance with the first embodiment. Theside pleats 91 of the bag 112 typically remain folded inwardly until thebag is filled. The end of the bag 112 includes a shear seal closure 114that includes both a pinch seal 116 and a foldover seal 118. Referringto FIGS. 12-14, 17 and 18, in the pinch seal 116:

-   -   all (e.g., substantially all) of the portions of the inner        portions I1, I3 that are in opposing face-to-face relation with        one another are in opposing face-to-face contact with one        another and are sealed to one another;    -   at each pleat 91, all (e.g., substantially all) of the surface        portions P1, P2 are in opposing face-to-face contact with one        another and are sealed to one another;    -   at each pleat 91, all (e.g., substantially all) of the surface        portion P3 and the inner portion I1 are in opposing face-to-face        contact with one another and are sealed to one another; and    -   at each pleat 91, all (e.g., substantially all) of the surface        portion P4 and the inner portion I3 are in opposing face-to-face        contact with one another and are sealed to one another.        In the foldover seal 118, all (e.g., substantially all) of the        outer portions O1, O2 are in opposing face-to-face contact with        one another and are sealed to one another. In accordance with        the first embodiment, when the sealing system 20 is used to form        the shear seal closure 114, the sealing system operates in a        manner that seeks to avoid formation of any seals in addition to        those discussed immediately above for the shear seal closure        114/pinch seal 116/foldover seal 118, in order to maximize the        volume of the interior of the bag 112. For example, unsealed        areas 94 are identified in FIGS. 17 and 18. Alternatively,        additional seals or sealed areas may be included.

An example of a method of forming the shear seal closure 114 isdescribed in the following, in accordance with the first embodiment. Theflattened tube 22, with its pleats 91 folded inwardly, is introducedinto the upstream end of the sealing system 20. The tube 22 isintroduced so that the longitudinal seal 93 faces forwardly (as shown inFIGS. 7 and 8) and the imaginary demarcation (e.g., see the respectivedashed line in FIG. 12) between the outer portions O1, O2 is atsubstantially the same elevation as the upstream diverter 46. Therefore,when the tube 22 engages the upstream diverter 46, the upstream diverterbegins to form a fold/fold line in the tube at the imaginary demarcationbetween the outer portions O1, O2. Then, as the partially folded tube 22continues to be carried downstream by the transport conveyor 26, the airoutlets 48 a, 48 b, 48 c (FIG. 4) are respectively in opposingface-to-face relation with and discharge hot air against the outerportions O3, O1 so that the outer portions O3, O1 are heated by forcedconvention. The air outlets 48 a, 48 b are opposite from one another.Similarly, the air outlets 48 a, 48 c are opposite from one another. Inaddition, the outer portions O3, O1 are opposite from one another.

The surfaces that are sealed together as part of the pinch seal 116(FIGS. 17 and 18) may comprise (or have applied to at least a portionthereof) a heat sealable and/or adhesive material, for example, a heatsealable polymer film, a heat sealable coating, a hot melt adhesive, orany other suitable material for forming the pinch seal 116, as needed tocreate the desired heat seal (e.g., to provide strength, protection fromcontamination or infestation by insects, and so on). When exposed toheat, the heat sealable and/or adhesive material is operative forjoining the surfaces that are sealed together as part of the pinch seal116. In accordance with the first embodiment, the pinch seal 116 extendsall the way (substantially all the way) from one side of the bag 112 tothe other side of the bag. However, it will be appreciated that thepinch seal 116 may be spaced from the opposite edges of the bag 112and/or may have other transverse and/or longitudinal dimensions.

The pinch seal 116 may generally be formed at a temperature below thedistortion or softening temperature of the woven polymer substrate 102(FIG. 15) and/or any other components of the packaging material 100 thatare not intended to be softened. For example, where the woven polymersubstrate 102 comprises polypropylene, which typically softens at about350° F., the heat seal temperature for forming the pinch seal 116 maygenerally be less than about 350° F., for example, from about 250° F. toabout 300° F., or to about 325° F. Accordingly, the air outlets 48 a, 48b, 48 c that are respectively in opposing face-to-face relation with anddischarge hot air against the outer portions O3, O1 provide the hot airat a temperature that is high enough to provide the heat sealtemperature for forming the pinch seal 116, yet not so high so as tocause the woven polymer substrate 102 to reach its softeningtemperature. The desired or required temperature of the hot airdischarged by the air outlets 48 a, 48 b, 48 c may depend upon variousfactors such as, but not limited to, the dwell time (e.g., how quicklythe tube 22 is transported through the sealing system 20).

As the partially folded, heated tube 22 continues to be carrieddownstream by the transport conveyor 26, the tube 22 engages thedownstream diverter 47 which completes (e.g., substantially completes)folding the tube so that the tube is in the folded-over configurationthat is schematically shown in FIG. 9 (e.g., the substantially onehundred eight degree folded-over configuration). As best understood withreference to FIG. 9 and for example, while the tube 22 is in thefolded-over configuration: the first and second outer portions O1, O2 ofthe tube 22 are facing substantially toward one another, and the thirdand fourth outer portions O3, O4 of the tube are facing substantiallyaway from one another.

At about the same time that the downstream diverter 47 substantiallyprovides the folded-over configuration of the tube 22, the air outlets48 d, 48 e, 48 f (FIG. 9) are respectively in opposing face-to-facerelation with and discharge air against the outer portions O1, O2, O4 sothat heat is transferred with respect to the outer portions O1, O2, O4by way of forced convention. The air outlets 48 d, 48 e are oppositefrom one another. Similarly, the air outlets 48 e, 48 f are oppositefrom one another. The air outlets 48 d, 48 f may also be characterizedas being opposite from one another. In addition, the outer portions O3,O1 are opposite from one another. While the tube 22 is in thefolded-over configuration, outer portions O1, O2 are opposite from oneanother. The outer portions O1, O4 may also be characterized as beingopposite from one another, and the outer portions O3, O2 may also becharacterized as being opposite from one another.

More specifically, the air outlets 48 d, 48 e discharge hot air againstthe outer portions O1, O2 so that the outer portions O1, O2 are heatedby forced convention; and the air outlet 48 f discharges cool air or airat ambient temperature (e.g., relatively cool air) against the outerportion O4 so that the outer portion O4 is cooled by forced convention.The above-discussed heating by forced convection is for helping tofacilitate forming of the above-discussed seals of the shear sealclosure, and the above-discussed cooling by forced convection is forhelping to avoid forming any more than the seal between the outerportions O1, O2 when the foldover seal 118 is formed.

The surfaces that are sealed together as part of the foldover seal 118may comprise (or have applied to at least a portion thereof) a heatsealable and/or adhesive material, for example, a heat sealable polymerfilm, a heat sealable coating, a hot melt adhesive, or any othersuitable material for forming the foldover seal 118, as needed to createthe desired heat seal (e.g., to provide strength, protection fromcontamination or infestation by insects, and so on). When exposed toheat, the heat sealable and/or adhesive material is operative forjoining the surfaces that are sealed together as part of the foldoverseal 118. In accordance with the first embodiment, the foldover seal 118extends all the way (substantially all the way) from one side of the bag112 to the other side of the bag. However, it will be appreciated thatthe foldover seal 118 may be spaced from the opposite edges of the bag112 and/or may have other transverse and/or longitudinal dimensions.

The foldover seal 118 may generally be formed at a temperature below thedistortion or softening temperature of the woven polymer substrate 102(FIG. 15) and/or any other components of the packaging material 100 thatare not intended to be heat sealed. For example, where the woven polymersubstrate 102 comprises polypropylene, which typically softens at about350° F., the heat seal temperature for forming the foldover seal 118 maygenerally be less than about 350° F., for example, from about 250° F. toabout 300° F., or to about 325° F. Accordingly, the air outlets 48 b, 48c, 48 d, 48 e, that are respectively in opposing face-to-face relationwith and discharge hot air against the outer portions O2, O1 provide thehot air at a temperature that is high enough to provide the heat sealtemperature for forming the foldover seal 118, yet not so high so as tocause the woven polymer substrate 102 to reach its softeningtemperature.

Reiterating from above, if needed, air substantially at ambienttemperature or cooled air may be directed by the air outlet 48 f againstthe outer portion O4 in a manner that seeks to prevent the interiorsurfaces 108 of the tube 22 from being joined to one another behind thefoldover seal 118 (which would reduce the volume of the interior spaceof the bag 112). However, other possibilities are contemplated. Thedesired or required temperature of the air discharged by the air outlets48 d, 48 e, 48 f may depend upon various factors such as, but notlimited to, the dwell time (e.g., how quickly the tube 22 is transportedthrough the sealing system 20).

The heat sealable and/or adhesive material may lie outside of the areain which the foldover seal 118 and the pinch seal 116 are to be formed.For example, all or a portion of the interior or exterior surfaces 108,110 of the tube 22 may comprise a heat sealable polymer film orpolymeric material.

The nipping apparatus 76 nips the upper portion of the tube 22 in thefolded-over configuration to simultaneously (e.g., substantiallysimultaneously) complete the formation of the pinch seal 116 and thefoldover seal 118. Then, the resulting bag 112 is discharged from thedownstream end of the sealing system 20/conveyor assembly 42/nippingapparatus 76.

A second embodiment of this disclosure is like the first embodiment,except for variations noted in this disclosure and variations that willbe apparent to one of ordinary skill in the art. FIG. 19 is a schematiccross-sectional view of a portion of a bag of the bag 112′ secondembodiment, with the cross section taken similarly to that of FIG. 17;and FIG. 20 is a schematic cross-sectional view of a portion of the bag112′ of the second embodiment, with the cross section taken similarly tothat of FIG. 18. The sealed closure of the bag 112′ of the secondembodiment is not folded over, and it only includes the pinch seal 116(i.e., the foldover seal 118 (FIGS. 17 and 18) is omitted). Inaccordance with one acceptable example, the closure of the bag 112′ ofthe second embodiment may be formed in the sealing system by 20 byintroducing the tube 22 so that the top edge of the tube is slightlybelow the elevation as the upstream diverter 46 (i.e., the tube is notfolded) and hot air is discharged by both of the air outlets 48 e, 48 f(FIG. 5). The other air outlets 48 a, 48 b, 48 c, 48 d may be disabledor otherwise not used, or the like. That is, it is within the scope ofthis disclosure for a user of the sealing system 20 to select the airoutlets to be used/not to be used, depending upon the circumstances. Forexample, dampers 70 (FIG. 6) and/or other types of valves and/or anyother suitable controlling devices may be included in the sealing system20, or more specifically in the forced air systems 58 (FIG. 6), forselectively controlling (e.g., disabling or enabling) flow to one ormore of the above-discussed plenums and/or air outlets.

A third embodiment of this disclosure is like the first embodiment,except for variations noted in this disclosure and variations that willbe apparent to one of ordinary skill in the art. FIG. 21 is a schematiccross-sectional view of a portion of a bag 112″ of the third embodiment,with the cross section taken similarly to that of FIG. 17; and FIG. 22is a schematic cross-sectional view of a portion of the bag 112″ of thethird embodiment, with the cross section taken similarly to that of FIG.18. In accordance with one acceptable example, the closure of the bag112″ of the third embodiment may be formed in the sealing system by 20by passing the upper end of the bag 112 of FIG. 16 through the sealingsystem a second time, to substantially repeat the method of the firstembodiment, and therefore form a double shear seal closure.

A fourth embodiment of this disclosure is like the third embodiment,except for variations noted in this disclosure and variations that willbe apparent to one of ordinary skill in the art. FIG. 23 is a schematiccross-sectional view of a portion of a bag 112′″ of the fourthembodiment, with the cross section taken similarly to that of FIG. 17.In the double shear seal closure of the bag 112′″ of the fourthembodiment, the end/pinch seal farthest from the interior of the bag isextended, and an integral grasping feature or handle generallycomprising an aperture 95 or cutout extends through the pinch sealfarthest from the interior of the bag. A flap may be retained in theaperture 95, such as for providing cushioning against a hand insertedinto the aperture.

Countless packaging materials 100 (FIG. 15) may be used in accordancewith the present disclosure to form any of the constructs and structures(e.g., tubes and bags) described above, with the substrate 102 andfacing systems 104, 106 being selected to impart various properties tothe resulting packaging material. By way of illustration, and notlimitation, several exemplary packaging materials 200, 300, 400 areillustrated schematically in FIGS. 24-26. Each packaging material 200,300, 400 generally includes a woven polymer substrate 202, 302, 402 anda respective pair of facing systems 104, 106; 204, 206; 304, 306, eachof which may include a plurality of layers, as discussed above inconnection with FIG. 15. For purposes of convenience, some layers of thepackaging materials 200, 300, 400 may be described as “overlying” orbeing disposed “on” other layers. However, it will be appreciated thateach packaging material 200, 300, 400 may be inverted, such that otherlayers may be said to “overlie” or be disposed “on” one another.Accordingly, such terminology is provided merely for convenience ofexplanation and not limitation in any manner.

It will also be appreciated that numerous other packaging materials arecontemplated by the disclosure, and that each of such packagingmaterials may include various layers. Layers may be added or omitted asneeded. It also will be appreciated that various materials may be usedto form each layer of the packaging material, and that each layer mayhave various basis weights or coat weights and may be present in thepackaging material in any suitable relative amount, depending on theparticular application. Further, it will be appreciated that each layermay serve more than one purpose in a particular packaging material, andthat the layer names are provided for convenience of explanation and notlimitation in any manner.

Turning now to FIG. 24, a first exemplary packaging material 200includes a woven polymer substrate 202, a first facing system 204comprising a first polymer film layer 212 and a tie layer (e.g., a firsttie layer) 214 disposed between the substrate 202 and the first polymerfilm layer 212, and a second facing system 206 comprising a secondpolymer film layer 216, which may be optionally printed with ink 218,and a tie layer (e.g., a second tie layer) 220 disposed between thesubstrate 202 and the second polymer film layer 216. Each layer 202,212, 214, 216, 218, 220 is in a substantially facing, contactingrelationship with the respective adjacent layer(s). Alternatively, inother embodiments, the second polymer film layer 216 may be reverseprinted such that the ink 218 lies between the second polymer film layer216 and the second tie layer 220.

When used to form a package, the first polymer film layer 212 (i.e., theoutermost surface of the first polymer film layer 212) generally facesinwardly and/or defines the interior surface 208 of the tube, bag,package or the like, and the second polymer film layer 216 (i.e., theoutermost surface of the second polymer film layer 216 and/or ink 218,where present) generally defines the exterior surface 210 of the tube,bag, package or the like. Accordingly, one or both polymer film layers212, 216 may comprise heat sealable materials.

The substrate 202 generally comprises a base material from which thepackaging material is formed. In one particular embodiment, thesubstrate 202 may comprise a woven polymer, for example, a wovenpolypropylene. The substrate 202 may have a denier of from about 600 toabout 1200 dpf (denier per filament), for example, from about 700 to1000 dpf, and in one example, the substrate 202 comprises a wovenmaterial having a denier of about 850 dpf. Likewise, the substrate 202may have any suitable weave, for example, from about 8×8 to about 12×12,for example, about 10×10. In one particular example, the substrate 202comprises a woven polypropylene having a denier of about 850 dpf and a10×10 weave. One example of such a material is commercially availablefrom Mayur Wovens Pvt., Ltd. (India). However, countless other deniers,ranges of deniers, weaves, ranges of weaves, and other substrates may beused.

The first polymer film layer 212 and the second polymer film layer 216may be used to impart strength, water resistance, heat sealability,and/or other attributes to the packaging material 200. Where heatsealability is desired, one or both polymer films 212, 216 may generallycomprise a thermoplastic polymer having a sufficiently low melting orsoftening point so the heat seal can be initiated at a relatively lowtemperature (“heat seal temperature”), for example, from about 180° F.to about 300° F. Additionally, the polymer may be selected to provide awide hot tack sealing window, such that the heat seal may be formed overa range of temperatures with the degree of tackiness for the desiredduration.

Examples of suitable polymers may include, for example, polypropylene(PP), for example, biaxially oriented polypropylene (BOPP) (e.g., BEM19BOPP film, Vifan USA, Inc., Morristown, Tenn.), polyethyleneterephthalate (PET), metallized polyethylene terephthalate, low densitypolyethylene (LDPE), poly(ethylene-co-methacrylic acid) (EMAA) (e.g.,Surlyn® films available from DuPont, Wilmington, Del.), or any othersuitable material.

The polymer film layers 212, 216 may generally have any suitablethickness (i.e., caliper), for example, from about 0.4 to about 1.5 mil,for example, from about 0.5 to about 1.2 mil. In one example, one orboth polymer film layers 212, 216 may have a thickness of about 0.7 mil.In another example, one or both polymer film layers 212, 216 may have athickness of about 1 mil. However, other suitable thicknesses and rangesof thicknesses are contemplated.

In one particular example, the first polymer film layer 212 may compriselow density polyethylene (LDPE). In one variation of this example, thefirst polymer film layer 212 may have a thickness of from about 0.5 toabout 3 mil, for example, from about 0.8 to about 1.5 mil, for example,about 1 mil. However, other suitable materials are contemplated.

In another particular example, the second polymer film layer 216 maycomprise biaxially oriented polypropylene (BOPP). In one variation ofthis example, the second polymer film layer 216 may have a thickness offrom about 0.4 to about 1 mil, for example, from about 0.6 to about 0.8mil, for example, about 0.7 mil. However, other suitable materials arecontemplated.

In still another particular example, the first polymer film layer 212may comprise LDPE having a thickness of from about 0.8 to about 1.5 mil,for example, about 1 mil, and the second polymer film layer 216 maycomprise BOPP having a thickness of from about 0.4 to about 1 mil, forexample, about 0.7 mil. However, numerous other configurations of layersare contemplated.

It will be appreciated that in an alternative embodiment, layers 212and/or 216 may be used to provide strength and/or water resistance,while one or more other layers (not shown) may be provided for heatsealability. Countless possibilities are contemplated.

The tie layers 214, 220 generally serve to join two adjacent layers, butmay have additional functionality if desired. In this example, tie layer214 is generally operative for joining the first polymer film layer 212and the substrate 202, and tie layer 220 is generally operative forjoining the second polymer film layer 216 and the substrate 202.

Each tie layer 214, 220 may have any suitable composition and basisweight needed to attain the desired level of adhesion between theadjacent layers. For example, where the adjacent layers comprise PP(e.g., layers 202, 216), tie layer 220 may comprise PP. One example of aPP that may be suitable as a tie layer 220 is HMX 370 or HMX 340,commercially available from Chevron.

As another example, where the adjacent layers (e.g., layers 202, 212)comprise PP (e.g., layer 202) and LDPE (e.g., layer 212), the tie layer214 may comprise a blend of polymers. The blend may include one or morecomponents that provide adhesion to the substrate 202 and one or morecomponents that provide adhesion to the first polymer film layer 212.

In one particular example, the blend may comprise a blend of linear lowdensity polyethylene (LLDPE), for example, metallocene catalyzed LLPDE(“m-LLDPE”) and LDPE. The present inventors have discovered that thisexemplary blend provides superior processability and adhesiveproperties. One example of an LLDPE that may be suitable for use is DowAffinity PT 1450G1 (Dow Chemical Co., Midland, Mich.) (believed to bem-LLDPE). While not wishing to be bound by theory, it is believed thatDow Affinity PT 1450G1 LLDPE may include one or more components that mayenhance the adhesion with PP. One example of an LDPE that may besuitable is Chevron 1018 LDPE (Chevron Phillips Chemical Co. LLC, TheWoodlands, Tex.). Other examples of LDPEs that may be suitable include,but are not limited to, Westlake EC-482 (Westlake Chemical Corp.,Houston, Tex.) and Marfiex® 1013 LDPE (Phillips Chemical Co. LLC, TheWoodlands, Tex.).

The relative amounts of LLDPE (e.g., m-LLDPE) and LDPE in the tie layer214 may vary for each application. The blend may generally comprise fromabout 70% to about 95% LLDPE and about 5% to about 30% LDPE (by weight),for example, from about 80% to about 90% LLDPE and about 10% to about20% LDPE. In one exemplary embodiment, the blend may comprise about 85%LLDPE and about 15% LDPE. However, other suitable amounts and ratios ofLDPE and PP may be used.

In other embodiments, the tie layer 214 may comprise a blend of PP andLDPE. Numerous other possibilities are contemplated.

Each tie layer 214, 220 may have any suitable basis weight, for example,from about 1 to about 15 lb/ream, for example, from about 6 to about 10lb/ream. In one specific example, one of the tie layers 214, 220 has abasis weight of about 8 lb/ream. In another example, both of the tielayers 214, 220 have a basis weight of from about 8 lb/ream. However,other basis weights and ranges of basis weights are contemplated.

FIG. 25 schematically illustrates another exemplary packaging material300. The packaging material 300 includes a substrate 302 including apair of opposed sides, a first facing system 304 including a tie layer312 (e.g., a first tie layer), a core layer 314, and a heat seal layer316 disposed on a first side of the substrate 302, and a second facingsystem 306 including a polymer film layer 318, which may optionally beprinted with an ink 320, and a tie layer 322 (e.g., a second tie layer)disposed on a second side of the substrate 302. In an alternativeembodiment (not shown), the polymer film layer 318 may include printing(i.e., ink 320) on the exterior surface 310 of the film 318.

Each layer or material 302, 312, 314, 316, 318, 320, 322 is in asubstantially facing, contacting relationship with the respectiveadjacent layer(s) or material. When used to form a package, polymer filmlayer 318 (i.e., the outermost surface 310 of polymer film layer 318)generally faces outwardly and/or at least partially defines the exteriorsurface 310 of the tube, bag, package or the like, and heat seal layer316 (i.e., the outermost surface 308 of heat seal layer 316) generallyfaces inwardly and/or defines the interior surface 308 of the tube, bag,package or the like.

The substrate 302 may be any suitable material, for example, the wovenpolymer materials described in connection with FIG. 24.

Layers 312, 314, 316 generally define a multifunctional polymer system304. The polymer system 304 may be used to impart numerous properties tothe packaging material 300. Thus, while the layers of the polymer system304 may be described independently, it will be appreciated that thelayers cooperate with one another to enhance the packaging material 300,as will be discussed below.

The heat seal layer 316 generally renders the interior side 308 of thepackaging material 300 heat sealable. This may be desirable for numerouspackage configurations. The core layer 314 generally comprises a polymerlayer, which may, if desired, impart various attributes to the packagingmaterial 300. By way of example, and not limitation, the core layer 314may serve as a barrier layer to oils (i.e., as an oil resistant layer).This may be important where the contents of the tube, bag, package orthe like include a fatty or oily component, for example, as with petfood, bird seed, etc. The tie layer 312 generally joins the core layer314 to the substrate 302. However, in some embodiments, the tie layermay be omitted, such that the core layer 314 also serves as a tie layer.

In some instances, the core layer 314 may be selected to have a meltingpoint that is greater than the heat seal temperature to ensure that theintegrity of the core layer 314 is maintained during the heat sealingprocess. In other instances, the core layer 314 may comprise a blend ofmaterials, at least one of which may have a melting point less than theheat seal temperature. In such embodiments, the lower meltingcomponent(s) may soften during the heat sealing process, such that aportion of the core layer 314 serves as a heat seal material or layer inconjunction with heat seal layer 316. Thus, depending on the materialsselected, each of the various layers 312, 314, 316 may cooperate invarious ways to achieve a desired result.

In one exemplary embodiment, the heat seal layer 316 may comprise ablend of low density polyethylene (LLDPE), low density polyethylene(LDPE), and an ethylene/methacrylic acid copolymer (EMA). The LLDPE maybe a metallocene LLDPE (m-LLDPE). The ratio of each component may varyfor each application. In one example, the blend may comprise from about60% to 100% LLDPE, from 0 to about 35% LDPE, and from 0 to about 5% EMA.In another example, the blend may comprise from about 60% to about 80%LLDPE, from about 15% to about 35% LDPE, and from about 1 to about 5%EMA. In still another example, the blend may comprise about 60% LLDPE,about 35% LDPE, and about 5% EMA, such that the ratio of the componentsis about 12:7:1. However, other blends of LLDPE, LDPE, and EMA arecontemplated.

The present inventors have found that a blend of LLDPE, LDPE, and EMAoffers superior processability and resulting heat seal strength.Specifically, the present inventors have found that by adding LLDPE toLDPE, the melting point (and, therefore, the heat seal temperature) islowered from about 230° F. to about 220° F., and that by adding EMA tothe mixture of LLDPE and LDPE, the melting point (and, therefore, theheat seal temperature) of the blend is lowered to about 210-215° F. As aresult, the heat seal may be initiated at a lower temperature, whichallows for the packaging material 300 to be heat sealed at greaterprocessing speeds. The present inventors have also found that the heatseal formed from the blend of LLDPE, LDPE, and EMA has superior strengthrelative to a heat seal formed from any of the individual components.

While various LLPDEs, LDPEs, and EMAs may be used, one example of anLLDPE that may be suitable for use is Dow Affinity PT 1450G1 (DowChemical Co., Midland, Mich.) (believed to be m-LLDPE). While notwishing to be bound by theory, it is believed that Dow Affinity PT1450G1 LLDPE may include one or more components that may enhance theaffinity with PP. One example of an LDPE that may be suitable is Chevron1018 LDPE (Chevron Phillips Chemical Co. LLC, The Woodlands, Tex.).Other examples of LDPEs that may be suitable are set forth above inconnection with the discussion of the exemplary packaging material 200of FIG. 24.

The heat seal layer 316 may have any suitable basis weight, for example,from about 1 to about 5 lb/ream, for example, from about 2 to about 4lb/ream, for example, about 3 lb/ream. In one specific example, the heatseal layer 316 has a basis weight of about 3.06 lb/ream. However, otherbasis weights and ranges thereof are contemplated.

The tie layer 312 may be formed from any suitable material thatsufficiently adheres to (and therefore joins) the adjacent layers. Inone example, the tie layer 312 may comprise a blend of LLDPE, LDPE, andEMA, as described above. The ratio of each component may vary for eachapplication. In one variation, the blend may comprise from about 60% to100% LLDPE, from 0 to about 35% LDPE, and from 0 to about 5% EMA. Inanother variation, the blend may comprise from about 60% to about 80%LLDPE, from about 15% to about 35% LDPE, and from about 1 to about 5%EMA. In still another variation, the blend may comprise about 60% LLDPE,about 35% LDPE, and about 5% EMA, such that the ratio of the componentsis about 12:7:1. Other blends of LLDPE, LDPE, and EMA are contemplated.

The present inventors have discovered that this exemplary blend providessuperior processability and adhesive properties with a variety ofsubstrates. By way of illustration, and not limitation, it is known thatit is difficult to adhere various polymers layers to polypropylene (PP)(e.g., in the substrate 302) at high processing speeds. However, theexemplary blend of LLDPE, LDPE, and EMA, which has a relatively lowmelting point (about 210-215° F. as compared with about 350° F. for PP),tends to flow readily into the spaces between the woven filaments, evenat high processing speeds (e.g., 2000-2500 ft/min). Additionally, whereDow Affinity 1450G1 LLPDE is used, the present inventors have found thatthe tie layer 312 has a greater affinity for core layers including PP(e.g., core layer 314), as compared with other LLDPEs. As stated above,while not wishing to be bound by theory, it is believed that the DowAffinity 1450G1 LLDPE includes one or more components that enhance theaffinity of the LLPDE to PP.

The tie layer 312 may have any suitable basis weight, for example, fromabout 0.5 to about 5 lb/ream, for example, from about 0.75 to about 2lb/ream, for example, about 1 lb/ream. In one specific example, the tielayer 312 has a basis weight of about 1.19 lb/ream. Other ranges andbasis weights are contemplated.

In one exemplary embodiment, the core layer 314 may comprise a blend ofPP and LDPE. The relative amounts of PP and LDPE in the core layer 314may vary for each application. The blend may generally comprise fromabout 70% to about 90% PP and about 10% to about 30% LDPE. In each ofvarious examples, the blend may comprise about 75% PP and about 25%LDPE, about 80% PP and about 20% LDPE, or about 85% PP and about 15%LDPE. However, other suitable amounts and ratios of LDPE and PP may beused.

The present inventors have discovered these exemplary blends of PP andLDPE in the core layer 314 provide an excellent balance of propertiesfor various packaging materials. For example, as compared with a corelayer 314 comprising only PP (i.e., without the LDPE), a core layer 314including from about 80 to about 85% PP and about 15 to 20% LDPE (byweight) provides about the same level of oil resistance as a core layer314 comprising 100% PP. Further, the presence of the LDPE improvesadhesion with the adjacent layers. By way of example, where the heatseal layer 316 and/or the tie layer 312 comprise a blend of LLDPE, LDPE,and EMA (e.g., as discussed above), the blend of LDPE and PP in the corelayer 314 has a greater affinity for the polymer blend of the heat seallayer 316 and/or the tie layer 312, as compared with PP alone.

Further, since LDPE has a lower melting point than PP (about 230° F. forLDPE and about 320° F. for PP), in some cases, depending on the heatseal temperature and other processing conditions, the LDPE in the corelayer 314 and the tie layer 312 may soften during the heat sealingprocess, such that a part of the core layer 314 and tie layer 312 alsoeffectively serves as part of the heat seal layer 316. In such cases,the basis weight of the heat seal layer 316 and/or the tie layer 312 maybe reduced, thereby reducing the cost of the overall structure.

By way of illustration, the present inventors have found that apackaging material including:

-   -   a heat seal layer 316 having a basis weight of about 1.3 lb/ream        and comprising a blend of about 60% LLDPE, about 35% LDPE, and        about 5% EMA (by weight);    -   a core layer 314 having a basis weight of about 3.33 lb/ream and        comprising an 80/20 blend of PP/LDPE; and    -   a tie layer 312 having a basis weight of about 0.37 lb/ream and        comprising a blend of about 60% LLDPE, about 35% LDPE, and about        5% EMA, exhibited better peel strength (i.e., layer to layer        adhesion) than a packaging material including:    -   a heat seal layer 316 having a basis weight of about 3.12        lb/ream and comprising a blend of about 60% LLDPE, about 35%        LDPE, and about 5% EMA;    -   a core layer 314 having a basis weight of about 4 lb/ream and        comprising PP; and    -   a tie layer 312 having a basis weight of about 0.88 lb/ream and        comprising a blend of about 60% LLDPE, about 35% LDPE, and about        5% EMA.        Thus, although each polymer system 304 had about the same basis        weight (about 5 lb/ream), the packaging material including the        blend of LDPE and PP in the core layer 314 exhibited superior        peel strength at a reduced cost (based on the present cost of        various polymers in each layer). While not wishing to be bound        by theory, it is believed that this is because the presence of        the LDPE in the core layer contributed to the overall heat        sealability of the material, as discussed above.

The core layer 314 may generally have a basis weight of from about 1 toabout 8 lb/ream, for example, from about 2 to about 6 lb/ream, forexample, about 4 lb/ream. In one specific example, the basis weight ofthe core layer 314 may be about 3.75 lb/ream. Other ranges and basisweights are contemplated.

The polymer system 304 (i.e., the heat seal layer 316, core layer 314,and tie layer 312) may have any suitable total basis weight. In each ofvarious examples, the polymer system 304 may have a basis weight ofabout 5 lb/ream, about 5.5 lb/ream, about 6 lb/ream, about 6.5 lb/ream,about 7 lb/ream, about 7.5 lb/ream, about 8 lb/ream, about 8.5 lb/ream,about 9 lb/ream, about 9.5 lb/ream, about 10 lb/ream, about 10.5lb/ream, about 11 lb/ream, about 11.5 lb/ream, about 12 lb/ream, about12.5 lb/ream, about 13 lb/ream, about 13.5 lb/ream, about 14 lb/ream,about 14.5 lb/ream, about 15 lb/ream, or any other suitable basisweight.

Further, the components of the polymer system 304 may be present in anysuitable ratio. In one example, the weight % ratio of the heat seallayer 316, core layer 314, and tie layer 312 may be about 3.06:3.15:1.However, other ratios are contemplated.

In one example, the heat seal layer 316 may have a basis weight of fromabout 1 to about 5 lb/ream, the core layer 314 may have a basis weightof from about 1 to about 8 lb/ream, and the tie layer 312 may have abasis weight of from about 0.5 to about 5 lb/ream.

In another example, the heat seal layer 316 may have a basis weight offrom about 2 to about 4 lb/ream, the core layer 314 may have a basisweight of from about 2 to about 6 lb/ream, and the tie layer 312 mayhave a basis weight of from about 0.75 to about 2 lb/ream. In oneparticular example, the heat seal layer 316 may have a basis weight ofabout 3 lb/ream, the core layer 314 may have a basis weight of about 4lb/ream, and the tie layer 312 may have a basis weight of about 1lb/ream. In another particular example, the heat seal layer 316 may havea basis weight of about 3.06 lb/ream, the core layer 314 may have abasis weight of about 3.75, and the tie layer 312 may have a basisweight of about 1.19 lb/ream.

The polymer film layer 318 may be used to impart strength, waterresistance, heat sealability, and/or other attributes to the packagingmaterial 300. Where heat sealability is desired, the polymer film 318may generally comprise a thermoplastic polymer having a sufficiently lowmelting or softening point so the heat seal can be initiated at arelatively low temperature (“heat seal temperature”), for example, fromabout 180° F. to about 300° F., as discussed above in connection withpolymer film layers 212, 216 of FIG. 24. Examples of polymers that maybe suitable for the polymer film layer 318 are also discussed inconnection with polymer film layers 212, 216 of FIG. 24.

The polymer film layer 318 may have any suitable thickness (i.e.,caliper) of, for example, from about 0.4 to about 1.5 mil, for example,from about 0.5 to about 1.2 mil. In one example, the film may have athickness of about 0.7 mil. However, other suitable thicknesses andranges of thicknesses are contemplated.

In one particular example, the polymer film layer 318 may comprisebiaxially oriented polypropylene (BOPP). In one variation of thisexample, the polymer film layer 318 may have a thickness of from about0.4 to about 1 mil, for example, from about 0.6 to about 0.8 mil. In onevariation of this example, the polymer film layer 318 may have athickness of about 0.7 mil. However, other suitable materials arecontemplated.

The tie layer 322 generally serves to join the two adjacent layers, inthis example, the polymer film layer 318 and the substrate 302, but mayprovide functionality if desired. The tie layer 322 may have anysuitable composition and basis weight as needed to attain the desiredlevel of adhesion between the adjacent layers. In one particularexample, the blend may comprise a blend of linear low densitypolyethylene (LLDPE), for example, metallocene catalyzed LLPDE(“m-LLDPE”) and LDPE. The present inventors have discovered that thisexemplary blend provides superior processability and adhesiveproperties. One example of an LLDPE that may be suitable for use is DowAffinity PT 1450G1 (Dow Chemical Co., Midland, Mich.) (believed to bem-LLDPE). While not wishing to be bound by theory, it is believed thatDow Affinity PT 1450G1 LLDPE may include one or more components that mayenhance the adhesion with PP. One example of an LDPE that may besuitable is Chevron 1018 LDPE (Chevron Phillips Chemical Co. LLC, TheWoodlands, Tex.). Other examples of LDPEs that may be suitable include,but are not limited to, Westlake EC-482 (Westlake Chemical Corp.,Houston, Tex.) and Marflex® 1013 LDPE (Phillips Chemical Co. LLC, TheWoodlands, Tex.). However, numerous other possible tie layers arecontemplated.

The relative amounts of LLDPE (e.g., m-LLDPE) and LDPE in the tie layer322 may vary for each application. The blend may generally comprise fromabout 70% to about 95% LLDPE and about 5% to about 30% LDPE (by weight),for example, from about 80% to about 90% LLDPE and about 10% to about20% LDPE. In one exemplary embodiment, the blend may comprise about 85%LLDPE and about 15% LDPE. However, other suitable amounts and ratios ofLDPE and PP may be used.

The tie layer 322 may have any suitable basis weight, for example, fromabout 1 to about 15 lb/ream, for example, from about 6 to about 10lb/ream. In one specific example, the tie layer 322 has a basis weightof about 8 lb/ream. However, other basis weights and ranges of basisweights are contemplated.

FIG. 26 schematically illustrates an alternate packaging material 400.The packaging material 400 includes features that are similar to thepackaging material 300 of FIG. 25, except for variations noted andvariations that will be understood by those of skill in the art. Forsimplicity, the reference numerals of similar features are preceded inthe figures with a “4” instead of a “3”.

In this example, layers 318, 320, 322 of the packaging material 300 ofFIG. 25 are replaced with a polymer system 406 similar to that ofpolymer system 404. Specifically, the packaging material 400 includes asubstrate 402 including a pair of opposed sides, a first tie layer 412,a first core layer 414, and a first heat seal layer 416 disposed on afirst side of the substrate 402, and a second tie layer 424, a secondcore layer 426, and a second heat seal layer 428 disposed on a secondside of the substrate 402, such that the arrangement of layers isgenerally symmetrical. If desired, the outermost surface 408, 410 oflayers 416 and/or 428 may be printed with ink (not shown).

Each pair of layers (e.g., the first and second heat seal layers 416,418, the first and second core layers 414, 426, and the first and secondtie layers 412, 424) independently may have the same or differentcomposition and/or weight. Exemplary basis weights are provided abovewith respect to the packaging material 300 of FIG. 25.

As with the packaging material 300 of FIG. 25, either or both of layers412, 424 may be omitted, such that layers 414, 426 serve as tie layersthat join the heat seal layers 416, 428 to the respective sides of thesubstrate 402.

While numerous possibilities are contemplated, this packaging material400 may find particular use where less strength is needed and/or where alower cost alternative is desired.

In still another exemplary embodiment (not shown), one or both of thefacing systems may comprise a layer of paper that defines the firstand/or second surface of the packaging material. It will be appreciatedthat shear seals and/or other seals may be formed from such materialsusing a hot melt adhesive or other adhesive material. Numerous otherpossibilities are contemplated.

Various aspects of the present invention are illustrated further by thefollowing example, which is not to be construed as limiting in anymanner.

Example 1

A packaging material having the following structure was made byextrusion laminating the polymer film layers to the woven substrate:

-   -   about 0.7 mil BOPP film;    -   about 8 lb/ream PP;    -   about 850 dpf 10×10 woven PP substrate;    -   about 8 lb/ream blend of 80% Dow Affinity m-LLDPE+20% LDPE;    -   about 1 mil LDPE film

Various properties of the packaging material were measured. The resultsare set forth in Table 1, in which all values are approximate.

TABLE 1 Weight (lb/ream)  66.2 Caliper (mils)  7.69 Grease resistance Nogrease penetration Oxygen transmission rate (OTR) (cc/m²/day)  16.01Water vapor transmission rate (WVTR)  0.105 (100 g/m²/day) Puncture (g)Would not puncture Gurley stiffness, MD 132.6 Gurley stiffness, CD 137.9Tear, MD (g) Would not tear Tear, CD (g) Would not tear Tensile, MD(lb/in) Would not break Tensile, CD (lb/in) Would not break

All directional references (e.g., upper, lower, upward, downward, left,right, leftward, rightward, top, bottom, above, below, vertical,horizontal, upstream and downstream) are used in the DetailedDescription section of this disclosure only for identification purposesto aid the reader's understanding of the various embodiments, and do notcreate limitations, particularly as to the position, orientation, or useof the invention unless specifically set forth in the following claims.

It will be understood by those skilled in the art that while the presentdisclosure has been discussed above with reference to severalembodiments, various additions, modifications and changes can be madethereto without departing from the spirit and scope of the invention asset forth in the claims.

1. A system for sealing a tube having opposite first and second sidesthat each extend between opposite ends of the tube, wherein the firstside of the tube includes a first outer portion of the tube and a secondouter portion of the tube, the second side of the tube includes a thirdouter portion of the tube and a fourth outer portion of the tube, andthe sealing system comprises: a transportation system for transportingthe tube in a downstream direction along a path; a folding apparatuspositioned along the path for moving the first and third outer portionsof the tube relative to the second and fourth outer portions of the tubeand, thereby, folding the tube into a folded-over configuration whilethe transportation system transports the tube proximate the foldingapparatus, wherein in the folded-over configuration the first and secondouter portions of the tube are facing substantially toward one another,and the third and fourth outer portions of the tube are facingsubstantially away from one another; a supplying apparatus positionedalong the path for being in opposing face-to-face relation with, and forcausing heat transfer with, at least one outer portion of the tube whilethe transportation system transports the tube proximate the supplyingapparatus, wherein the at least one outer portion of the tube isselected from the group consisting of the second outer portion of thetube, the third outer portion of the tube, and the fourth outer portionof the tube; and a nipping apparatus positioned downstream from both thefolding apparatus and the supplying apparatus along the path, forreceiving the tube in the folded-over configuration from thetransportation system, wherein the nipping apparatus is for nipping atleast the first, second, third and fourth outer portions of the tubewhile the tube is in the folded-over configuration.
 2. The sealingsystem according to claim 1, wherein: the supplying apparatus comprisesan air outlet mounted for being in opposing face-to-face relation withthe at least one outer portion of the tube while the transportationsystem transports the tube proximate the air outlet; and the air outletis for discharging air onto the at least one outer portion of the tubewhile the transportation system transports the tube proximate the airoutlet, so that forced convection causes heat transfer with the at leastone outer portion of the tube.
 3. The sealing system according to claim1, wherein: the supplying apparatus comprises a plenum includingopposite first and second faces that each include discharge ports fordischarging hot air; the first face is positioned along the path forbeing in opposing face-to-face relation with, and supplying hot air to,the first outer portion of the tube while the transportation systemtransports the tube, in its folded-over configuration, proximate theplenum; and the second face is positioned along the path for being inopposing face-to-face relation with, and supplying hot air to, thesecond outer portion of the tube while the transportation systemtransports the tube, in its folded-over configuration, proximate theplenum.
 4. The sealing system according to claim 3, wherein each of thefirst and second faces extend upright.
 5. The sealing system accordingto claim 4, wherein each of the first and second faces extend obliquelyto one another.
 6. The sealing system according to claim 1, wherein thesupplying apparatus includes an air outlet positioned along the path fordischarging air onto the at least one outer portion of the tube whilethe transportation system transports the tube proximate the air outlet.7. The sealing system according to claim 6, wherein: the foldingapparatus includes an upstream diverter positioned along the path forcarrying out a portion of the folding of the tube into the folded-overconfiguration while the transportation system transports the tubeproximate the upstream diverter, and a downstream diverter positionedalong the path for carrying out a portion of the folding of the tubeinto the folded-over configuration while the transportation systemtransports the tube proximate the downstream diverter; the downstreamdiverter is positioned downstream from the upstream diverter along thepath; and substantially all of the air outlet of the supplying apparatusis positioned downstream from the upstream diverter along the path. 8.The sealing system according to claim 6, wherein: the air outlet ismounted for being in opposing face-to-face relation with the fourthouter portion of the tube while the transportation system transports thetube proximate the air outlet; the supplying apparatus is part of aforced air system that includes an air mover for causing the air toflow; and the forced air system is operative for causing the air to bedischarged from the air outlet onto the fourth outer portion of the tubewhile the transportation system transports the tube proximate the airoutlet, so that heat is transferred away from the fourth outer portionof the tube by way of forced convection.
 9. The sealing system accordingto claim 8, wherein: the air outlet is a first air outlet; the sealingsystem further includes a second air outlet positioned along the pathfor being in opposing face-to-face relation with the first outer portionof the tube while the transportation system is transporting the tubeproximate the second air outlet, and discharging hot air onto the firstouter portion of the tube while the transportation system istransporting the tube proximate the second air outlet; and at least aportion of the first air outlet is positioned downstream from the secondair outlet along the path.
 10. The sealing system according to claim 8,wherein: the folding apparatus includes an upstream diverter positionedalong the path for carrying out a portion of the folding of the tubeinto the folded-over configuration while the transportation systemtransports the tube proximate the upstream diverter, and a downstreamdiverter positioned along the path for carrying out a portion of thefolding of the tube into the folded-over configuration while thetransportation system transports the tube proximate the downstreamdiverter; the downstream diverter is positioned downstream from theupstream diverter along the path; and the air outlet is at leastpartially covered by the downstream diverter.
 11. The sealing systemaccording to claim 8, further comprising a guide rail that extends alongthe path for guiding the tube along the path while the transportationsystem transports the tube along the guide rail, wherein thetransportation system includes a transport conveyor that extends alongthe path, the guide rail is positioned above the transport conveyor, andthe air outlet is proximate the guide rail.
 12. The sealing systemaccording to claim 8, wherein the supplying apparatus includes a coolerfor cooling the air before the air is discharged from the air outletonto the fourth outer portion of the tube while the transportationsystem transports the tube proximate the air outlet.
 13. The sealingsystem according to claim 6, wherein: the air outlet is mounted forbeing in opposing face-to-face relation with the second outer portion ofthe tube while the transportation system transports the tube proximatethe air outlet; the supplying apparatus is part of a forced air systemthat further includes an air mover for causing the air to flow, and aheater for heating the air; and the forced air system is operative forcausing the heated air to be discharged from the air outlet onto thesecond outer portion of the tube while the transportation systemtransports the tube proximate the air outlet, so that heat istransferred to the second outer portion of the tube by way of forcedconvection.
 14. The sealing system according to claim 13, furthercomprising a guide rail that extends along the path for guiding the tubealong the path while the transportation system transports the tube alongthe guide rail, wherein: the transportation system includes a transportconveyor that extends along the path; the guide rail is positioned abovethe transport conveyor; and an opening extends through the guide rail;the air outlet is proximate the guide rail for discharging the heatedair through the opening in the guide rail.
 15. The sealing systemaccording to claim 13, wherein: the folding apparatus includes anupstream diverter positioned along the path for carrying out a portionof the folding of the tube into the folded-over configuration while thetransportation system transports the tube proximate the upstreamdiverter, and a downstream diverter positioned along the path forcarrying out a portion of the folding of the tube into the folded-overconfiguration while the transportation system transports the tubeproximate the downstream diverter; the downstream diverter is positioneddownstream from the upstream diverter along the path; and the air outletis at least partially covered by the downstream diverter.
 16. Thesealing system according to claim 6, wherein: the air outlet is mountedfor being in opposing face-to-face relation with the third outer portionof the tube while the transportation system transports the tubeproximate the air outlet; the supplying apparatus is part of a forcedair system that further includes an air mover for causing the air toflow, and a heater for heating the air; and the forced air system isoperative for causing the heated air to be discharged from the airoutlet onto the third outer portion of the tube while the transportationsystem transports the tube proximate the air outlet, so that heat istransferred to the third outer portion of the tube by way of forcedconvection.
 17. The sealing system according to claim 16, wherein: thefolding apparatus includes an upstream diverter positioned along thepath for carrying out a portion of the folding of the tube into thefolded-over configuration while the transportation system transports thetube proximate the upstream diverter, and a downstream diverterpositioned along the path for carrying out a portion of the folding ofthe tube into the folded-over configuration while the transportationsystem transports the tube proximate the downstream diverter; thedownstream diverter is positioned downstream from the upstream diverteralong the path; and the air outlet is positioned between the upstreamand downstream diverters.
 18. The sealing system according to claim 17,comprising: a guide channel that extends along the path for guiding thetube along the path while the transportation system transports the tubein the downstream direction along the path; and a cover that ispivotably mounted for at least partially covering the guide channel,wherein the air outlet, the upstream diverter and the downstreamdiverter are carried proximate the cover for pivoting with the cover.19. A system for sealing a tube, the sealing system comprising: atransportation system for transporting the tube in a downstreamdirection along a path; a first supplying apparatus positioned along thepath for being in opposing face-to-face relation with, and for causingheat transfer with, a first outer portion of the tube while thetransportation system transports the tube proximate the first supplyingapparatus; a second supplying apparatus positioned along the path forbeing in opposing face-to-face relation with, and for causing heattransfer with, a second outer portion of the tube while thetransportation system transports the tube proximate the second supplyingapparatus, wherein the first and second supplying apparatuses areopposite from one another, and the first and second outer portions ofthe tube are opposite from one another; and a nipping apparatuspositioned downstream from both the first and second supplyingapparatuses, for receiving the tube from the transportation system,wherein the nipping apparatus is for nipping at least the first andsecond outer portions of the tube.
 20. The sealing system according toclaim 19, wherein for each supplying apparatus of the first and secondsupplying apparatuses and a respective outer portion of the tube of thefirst and second outer portions of the tube: the supplying apparatuscomprises an air outlet mounted for being in opposing face-to-facerelation with the respective outer portion of the tube while thetransportation system transports the tube proximate the air outlet; andthe air outlet is for discharging air onto the respective outer portionof the tube while the transportation system transports the tubeproximate the air outlet, so that forced convection causes heat transferwith the at least one outer portion of the tube.
 21. A method forsealing a tube, comprising: transporting the tube in a downstreamdirection along a path, wherein the tube has opposite first and secondsides that each extend between opposite ends of the tube, the first sideof the tube includes a first outer portion of the tube and a secondouter portion of the tube, and the second side of the tube includes athird outer portion of the tube and a fourth outer portion of the tube;folding the tube during the transporting of the tube in the downstreamdirection along the path, wherein the folding of the tube comprisesmoving the first and third outer portions of the tube relative to thesecond and fourth outer portions of the tube and, thereby, folding thetube into a folded-over configuration in which the first and secondouter portions of the tube are facing toward one another, and the thirdand fourth outer portions of the tube are facing away from one another;causing heat to be transferred with respect to at least one outerportion of the tube during the transporting of the tube in thedownstream direction along the path, wherein the at least one outerportion of the tube is selected from the group consisting of the secondouter portion of the tube, the third outer portion of the tube, and thefourth outer portion of the tube; and then nipping at least the first,second, third and fourth outer portions of the tube during thetransporting of the tube in the downstream direction along the path. 22.The method according to claim 21, wherein the tube comprises a wovenpolymer material.
 23. The method according to claim 21, wherein thecausing of the heat to be transferred with respect to the at least oneouter portion of the tube comprises: forcing air onto the at least oneouter portion of the tube, so that forced convection causes heattransfer with the at least one outer portion of the tube.
 24. A methodfor sealing a tube, comprising: transporting the tube in a downstreamdirection along a path; causing forced convective heat transfer with afirst outer portion of the tube during the transporting of the tube inthe downstream direction along the path; causing forced convective heattransfer with a second outer portion of the tube during the transportingof the tube in the downstream direction along the path, wherein thefirst and second outer portions of the tube are opposite from oneanother; and then nipping at least the first and second outer portionsof the tube during the transporting of the tube in the downstreamdirection along the path.
 25. The method according to claim 24, whereinthe tube comprises a woven polymer material.
 26. The method according toclaim 24, wherein: the causing of the forced convective heat transferwith the first outer portion of the tube comprises causing the air toflow in a first direction onto the first outer portion of the tube; thecausing of the forced convective heat transfer with the second outerportion of the tube comprises causing the air to flow in a seconddirection onto the second outer portion of the tube; and the first andsecond directions are opposite from one another.